Modern EV components in a classic mini-bus.
In the summer of 2023, I was asked to join a project at the EV Learning Center (EVLC) to convert a classic VW Bus to electric drive. The bus would go on to be a promotional piece for the EVLC, showing people that it is possible to learn the skills to build an EV yourself. So far, the bus has been a hit at several car shows.
The bus was put on rolling casters to get some ground clearance and maneuverability. With the engine removed from the rear, it was relatively easy to get at the important parts.
The bus used six Tesla Model S battery modules for a combined voltage of roughly 150V. The combined capacity was roughly 30kWh, which can provide lots of range. The batteries were sourced from salvaged Model S packs by EV West.
After we sealed the battery box up, all the members of the project signed the top cover before it went into the car.
Taking a quick selfie with the battery box before it's loaded into the bus.
Since the battery box weighed roughly 400lbs, getting it maneuvered into place was a very tedious job. We had to use the combined weight of several people to keep the cart in place while the battery was loaded in at a cantilever for clearance.
A group photo of some of the members of the project, including myself standing on the far left
Since this bus was using a prototype Tesla-type NACS charge port (provided by EV West), we needed a custom 3D-printed adapter to have it properly mated to where the previous gasoline intake was. The adapter was printed in PETG so as to be more heat resistant than typical PLA.
One of the main components I was responsible for was the assisted braking system. With the old engine removed, there was nothing left to produce the vacuum pressure the brake booster needs to function. Using a salvaged Tesla vacuum pump, I was able to get braking back to comfortable levels.
This is a photo of the underside of the engine bay, where my vacuum pump resides. It incorporates the vacuum pump, relays, and a pressure switch to turn the pump off when acceptable vacuum is achieved. The electric drive motor is visible on the left, which is a Netgain Motors Hyper9 HV producing roughly 90kW of power.
The bus on display in the Electric Avenue section of the 2023 Vista Rod Run car show. Driving the bus here was a bit terrifying as we later found out the steering was completely out of alignment and the box was about to go.